Method for manufacture a metallic component by pre-manufactured bodies

ABSTRACT

A method for manufacturing a metallic component including the steps of providing a capsule, which defines at least a portion of the shape of the metallic component, arranging metallic material in the capsule, sealing the capsule, subjecting the capsule to Hot Isostatic Pressing for a predetermined time, at a predetermined pressure and at a predetermined temperature, and optionally, removing the capsule. The metallic material is at least one pre-manufactured coherent body, which pre-manufactured coherent body being made of metallic powder, wherein at least a portion of the metallic powder is consolidated such that the metallic powder is held together into a pre-manufactured coherent body. At least one portion of the pre-manufactured coherent body is manufactured by Additive Manufacturing by subsequently arranging superimposed layers of metallic powder.

RELATED APPLICATION DATA

This application is a continuation application of U.S. application Ser.No. 15/300,854 filed on Sep. 30, 2016, which is a § 371 National StageApplication of PCT International Application No. PCT/EP2015/057229 filedApr. 1, 2015, claiming priority of EP Application No. 14163177.0 filedApr. 2, 2014, the entire contents of each of these applications areincorporated herein by reference by reference.

TECHNICAL FIELD

The present disclosure relates to a method for manufacturing a metalliccomponent.

BACKGROUND ART

Hot Isostatic Pressing (HIP) is a preferred method for manufacturingcomponents of near net shape and in high performance materials. In HIP,a capsule is defining the shape of the component and is typicallymanufactured from steel sheets. The capsule is filled with metal- orcomposite powder and subjected to high temperature and high isostaticpressure so that the metal powder bond metallurgically to a densecomponent of forge like strength.

Hot Isostatic Pressing is suitable for manufacturing components havingregions of different material. Typically, such components aremanufactured by adding the different materials in powder form into thecapsule. To achieve the desired properties of each separate material, itis thereby critical to avoid mixing of the different powders.

A common technique to position the different powders in the capsule isto use a filling template during powder filling and then remove thetemplate prior to sealing the capsule. A drawback with this technique isthat it is quite difficult to control powder separation when thetemplate is removed. The technique is also quite limited with regards tosize and geometry of the different powder regions.

Attempts have been made to facilitate manufacturing of components havingregions of different material. For example, WO2010/114474 shows a methodin which bodies of polymer material and metal powder are manufacturedand then placed in selected regions in the HIP capsule. However,although proven successful, this method is time consuming since thepolymer material in the bodies needs to be removed prior to HIP. Themethod may further result in carbon rich residues in the capsule.

Consequently, it is an aspect of the present disclosure to achieve amethod for manufacturing metallic components which remedies or at leastovercomes one or more problems of the prior art.

In particular, it is an aspect of the present disclosure to achieve amethod which allows for effective production for metallic componentswith HIP. A further aspect of the present disclosure is to provide animproved method for manufacturing of a metallic component with regionsof different materials.

Definitions

By “metallic materials” is meant materials which are metals orcomposites of metals and non-metallic phases or particles. Examples, butnot limiting, of metals are pure metals or alloys of metals and otherelements, such as steel. An example of composite material is MetalMatrix Composites which comprises hard particles, such as, but notlimiting to WC, TiC, TaC, TiN or hard phases in a metal matrix, such as,but not limiting to, Ni, Co, Fe, Cr.

By “coherent body which consists of metallic powder material” or“coherent body” as used herein interchangeably is meant a body havingsufficient strength to be allowed to be handled manually, i.e. by hand,without breaking.

SUMMARY OF THE DISCLOSURE

According to the present disclosure, at least one of the above mentionedaspects is met by a method for manufacturing a metallic componentcomprising the steps:

-   -   providing 100 a capsule 5 which defines at least a portion of        the shape of the metallic component 50; arranging 200 metallic        material 7 in the capsule 5; sealing 300 the capsule 5;        subjecting 400 the capsule 5 to Hot Isostatic Pressing for a        predetermined time, at a predetermined pressure and at a        predetermined temperature; optionally, removing 500 the capsule        5; characterized in that the metallic material 7 comprises at        least one pre-manufactured coherent body 1, 2, 3, 4 in which the        pre-manufactured coherent body 1, 2, 3, 4 consists of metallic        powder wherein at least a portion of the metallic powder is        consolidated such that the metallic powder is held together into        a pre-manufactured coherent body 1, 2, 3, 4 and wherein at least        one portion of the pre-manufactured coherent body 1. 2, 3, 4 is        manufactured by Additive Manufacturing by subsequently arranging        superimposed layers of metallic powder.

The Additive Manufacturing is a technique wherein discrete layers ofmetallic powder are continuously placed on top of each other until thepreformed body is formed. This technique allows for manufacturing ofbodies of complicated geometries. According the present method asdefined hereinabove or hereinafter the Additive Manufacturing may be 3Dprinting.

According to the present disclosure, more than one portion of thepre-manufactured coherent body 1, 2, 3, 4 are manufactured by AdditiveManufacturing, such as two or three portions of the pre-manufacturedcoherent body 1, 2, 3, 4 are manufactured by Additive Manufacturing.According to a further embodiment of the method as defined hereinaboveor hereinafter, the pre-manufactured coherent body 1, 2, 3, 4 ismanufactured by Additive Manufacturing, i.e. all of saidpre-manufactured coherent body 1, 2, 3, 4 is manufactured by AdditiveManufacturing.

The pre-manufactured coherent body 1, 2, 3, 4 used in the method asdefined hereinabove or hereinafter may be handled without the risk ofbreaking. This makes it possible to position the pre-manufacturedcoherent body with high accuracy in the HIP capsule and when severalbodies of different materials, such as two or more, are arranged in thecapsule, there is no risk that the different materials mix.

The entire pre-manufactured coherent body 1, 2, 3, 4 may consist ofsintered metallic powder. Hence, the entire pre-manufactured coherentbody 1, 2, 3, 4 may be consolidated by sintering. Sintering is aneffective method for achieving sufficient strength in thepre-manufactured coherent body. Moreover, by selecting an appropriatesintering temperature, the final sintered body may be given a porositywhich closely matches the porosity of loose metallic powder. Therefore,when the capsule also is filled with loose metallic powder, the sinteredbody will shrink and deform in a manner equal to the loose metallicpowder. This, in turn will result in homogenous and predictabledeformation of the final component.

According to an alternative, only a surface portion of thepre-manufactured coherent body 1, 2, 3, 4 may be consolidated. Thus, thesurface portion of pre-manufactured coherent body 1, 2, 3, 4 willconsist of consolidated metallic powder.

Furthermore, according to one alternative, a binder is added to thesurface portion of the pre-manufactured coherent body 1, 2, 3, 4 beforeAdditive Manufacturing by subsequently arranging superimposed layers ofmetallic powder and binder. The binder may be driven off by e.g. heattreatment before sintering is performed.

According to an alternative, the metallic powder in a surface portion ofthe pre-manufactured coherent body may be consolidated by meltingfollowed by cooling. Further, according to the present method as definedhereinabove or hereinafter, parts of the pre-manufactured body 1, 2, 3,4 may be consolidated by using laser beam or electron beam irradiation,such as the surf ace portion.

The method as defined hereinabove or hereinafter may be employed formanufacturing valve spindle 50, comprising a valve disc 52 and a valvestem 53, wherein

-   -   the capsule 5 defines at least a portion of the valve disc 52;    -   the metallic material 7 consists of a valve seat 1, a core body        2 which comprises a core head 11 which defines an inner portion        of the valve disc 52, a cladding layer 4 and a buffer layer 3        which is arranged on the core head 11; wherein, at least one of        the valve seat 1, the buffer layer 3 and the cladding layer 4        are coherent pre-manufactured bodies of metallic powder.

According to an alternative, two of the valve seat 1, the buffer layer 3and the cladding layer 4 may be coherent pre-manufactured bodies ofmetallic powder and the remaining metallic material may be loosemetallic powder. Thereby is achieved that the valve spindle, which has arather complicated design with three components of different materialsmay be manufactured without the risk of mixing the different materials.The pre manufactured bodies are preferably sintered, which incombination with loose powder results in homogenous and predictabledeformation of the HIP:ed valve spindle.

For example, at least the valve seat 1 and the buffer layer 3 arecoherent pre-manufactured bodies of metallic powder and the claddinglayer 4 is loose metallic powder. Alternatively, at least the valve seat1 and the cladding layer 4 are coherent pre-manufactured bodies ofmetallic powder and the buffer layer 3 is loose metallic powder.Alternatively, at least the buffer layer and 3 and the cladding layer 4are coherent pre-manufactured bodies of metallic powder and the valveseat is loose metallic powder. Alternatively, at least the valve seat 1,the buffer layer 3 and the cladding layer 4 are coherentpre-manufactured bodies of metallic powder.

The core body 2 may also be a pre-manufactured coherent body of metallicpowder. However, the core body may also be manufactured by forging ofsolid metallic material.

According to the present method as defined hereinabove or hereinafter,the valve seat 1 and/or the buffer layer 3 and/or the cladding layer 4are pre-manufactured by sintering metallic powder, wherein sintering isperformed at a temperature below the melting point of the metallicpowder and at atmospheric pressure. In the case the core body 2 is apre-manufactured body of metallic powder also the core body 2 is may besintered.

A binder may also be added to, apart for the surface portion of thepre-manufactured coherent body 1, 2, 3, 4, other portion of thepre-manufactured coherent body 1, 2, 3, 4. The function of the additionof the binder to the other portions of the pre-manufactured coherentbody 1, 2, 3, 4 is to provide for the manually handling of thepre-manufactured coherent body 1, 2, 3, 4, i.e. that said body may behandled by hand, without breaking.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1-3: Shows schematically the main steps of the present method.

FIG. 4: Shows schematically a component obtained by the present method.

FIG. 5: Shows schematically a pre-manufactured body according to anembodiment.

FIG. 6: A flow chart showing the order of the main steps of the presentmethod.

DETAILED DESCRIPTION OF EMBODIMENTS

The method as defined hereinabove and hereinafter will in the followingbe described in detail with reference to the manufacturing of a metalliccomponent in the form of a valve spindle. The general order of the mainsteps of the inventive method is shown in the flow chart of FIG. 6.

The described embodiment relates to the manufacturing of a valve spindlefor two-stroke marine diesel engines. However, this is not to beunderstood as limiting for the present disclosure, it should beappreciated that the inventive method is suitable for the manufacturingof all types of metallic components, for example impellers, fuelnozzles, rotor shafts and stress-o-meter rings.

FIG. 4 shows schematically, in cross-section, a perspective view of avalve spindle 50 obtained by the present method. The valve spindle 50comprises a stem 53 and valve disc 52. The valve disc has a flat uppersurface 54, which in the engine faces the cylinder room. The flatsurface 54 is also called the exhaust surface. Seen in cross-section,the valve spindle 50 comprises a core body 2 having a core head 11 whichis integrated in the valve disc 2 so that the core head 11 forms aninner portion of the valve disc 52. The core body 2 also comprises astem portion 12 which forms the stem 53 of the valve spindle. The valvespindle 50 further comprises a valve seat 3, a buffer layer 1 and acorrosion resistant cladding 4. The buffer layer 1 is arranged on thecore body. In particular the buffer layer 1 is arranged on the core head11 between the core head 11 and the corrosion resistant cladding 4 andbetween the valve seat 3 and the core head 11 to prevent diffusion ofcarbon from the core head 11 to the corrosion resistant cladding 4 or tothe valve seat 3. Carbon has a negative effect on the corrosionresistance and the mechanical properties of the cladding and the valveseat 3. The corrosion resistant cladding 4 covers the buffer layer andthe valve seat and forms the outer surface of the valve disc 52 of thevalve spindle 50.

In a first step 100 of the present method, see FIG. 1, a capsule 5,which defines at least a portion of the outer shape or contour of thevalve spindle is provided. The capsule 5 is manufactured from steelsheets that have been shaped into a suitable form by e.g. pressing orspin forming and then welded together. Preferably, the steel sheets aremanufactured from steel having a low content of carbon. For example, alow carbon steel having a carbon content of 0-0.09 wt % carbon. Examplesof suitable steel for the capsule are the commercially available steelsDC04, DC05 or DC06 available from the company SSAB. Such steels aresuitable as they provide a minimum of carbon diffusion to the valvespindle. A further advantage of these steel grades is that they mayeasily be removed by pickling in acid. The capsule 5 is of circularcross-section and consists of a lower cylindrical portion having theform of the stem 53 of the valve spindle 50. The upper portion of thecapsule 5 has the form of the valve disc 52 of the valve spindle 1.

In a second step 200, see FIG. 2, metallic material 7 is arranged incapsule. The metallic material consists of a valve seat 1, a core body2, a buffer layer 3 and a cladding layer 4.

The valve seat 1 is manufactured from the commercially available alloyInconel 718. This material has high toughness, high hardness and goodresistance to hot corrosion. Other suitable materials includesprecipitation hardening alloys, such as nickel base- or cobalt basealloys comprising one or several of the elements molybdenum, chromium,niobium, aluminum or titanium. Another example of a suitable alloy forthe valve seat is Ni40Cr3.5NbTi.

The preformed core body 2 may be manufactured from alloyed steel havinga carbon content of from 0.15-0-35 wt %. One example of a suitable steelfor the preformed core body may be the commercially availableSNCrW-steel. The pre-formed core body 2 may also be manufactured byusing Additive Manufacturing. The pre-formed core body 2 may alsomanufactured by forging.

The buffer layer 3 is arranged onto the head 11 of the core body 2. Thebuffer layer 3 covers the upper side and the edge portion of the corehead 11. The buffer layer 3 may consist of low carbon steel, having acarbon content of from 0-0.09 wt % carbon. The buffer layer may furtherbe alloyed with chromium in an amount of from 12-25 wt % for example offrom 14-20 wt %. One suitable material for the buffer layer is thecommercially available 316L-steel. In principle, the buffer layerabsorbs carbon from the core element and binds the carbon in the bufferlayer through the formation of chromium rich carbides. The buffer layershould be thick enough to form a continuous layer between the coreelement and the valve seat. The thickness of the buffer layer furtherdepends on the amount of carbon in the core element and the operationalconditions in the engine, for example the thickness of the buffer layeris in the range of from 2-10 mm, such as of from 3-7 mm, such as of from3 mm or 5 mm.

On top of the buffer layer 3 is a cladding layer 4 arranged. Thecladding layer 4 forms the exhaust side 4 and the peripheral portion ofthe valve disc 52. The cladding layer is manufactured from a highlycorrosion resistant alloy, The alloy may be a nickel based alloycomprising Cr, Nb, Al and Mo. Examples of suitable alloys for thecladding layer are the commercially available alloys Ni₄₉Cr1Nb orInconel 657.

According to the disclosure, at least one of the valve seat 1, the corebody 2, the buffer layer 3 and the cladding layer 4 is apre-manufactured coherent body consisting of metallic powder which hasbeen consolidated such that the metallic powder is held together into acoherent body. That is, the bodies 1, 2, 3, 4 are sufficiently strong tobe handled manually, i.e. picked up by hand and placed in the capsulewithout breaking. Each of the bodies 1, 2, 3, 4 may be apre-manufactured coherent body consisting of metallic powder. It is alsopossible that two or three bodies 1, 2, 3, 4 are pre-manufacturedcoherent bodies consisting of metallic powder and that the remainingbody or bodies are provided as loose powder, i.e. powder which is notadhered or bonded. The metallic powder used is as described in theprevious sections. Hence, the valve seat 1 may consist of a loose orconsolidated powder of Inconel 718. The buffer layer 3 may consist of apowder of 316L-steel, the cladding layer 4 may consist of a loose orconsolidated powder of Inconel 657 and the core body may consist of aloose or consolidated powder of SNCrW-steel. However, typically the corebody is manufactured by forging a solid piece of steel such asSNCrW-steel.

The at least one portion of the pre-manufactured coherent bodies 1, 2,3, 4 is manufactured by Additive Manufacturing, such as 3D-printing.According to one embodiment of the present disclosure more than oneportion of the pre-manufactured coherent bodies 1, 2, 3, 4 may bemanufactured by Additive Manufacturing. According to yet anotherembodiment, the pre-manufactured coherent bodies 1. 2, 3, 4 aremanufactured by Additive Manufacturing.

Generally, in Additive Manufacturing a body may be built up by discretelayers of a mixture of metallic powder and binder that are laid on topof each other. The binder is driven off from the body and the body issintered into a coherent state. If the Additive Manufacturing is3D-printing, the 3D-printing may for example be performed in the3D-printing machine “Exone M-Print” which is commercially available fromthe company Exone Inc.

If the bodies 1, 2, 3, 4 are to be sintered, they are placed in asintering furnace which is heated to a temperature below the meltingpoint of the metallic powder. Sintering is performed in atmosphericpressure or vacuum and at low sintering temperatures to avoid that thebody is densified. The exact temperature has to be determined for eachmetallic material in question. During sintering the contact surfaces ofthe metallic powder particles adhere to each other and after cooling apre-manufactured coherent body is achieved. Since it is sintered thebody is porous, i.e. it has a porosity of 60-80 vol %, for example 65-75vol %. The degree of porosity in the sintered pre-manufactured body maybe influenced by sintering temperature. Further, if the bodies 1, 2, 3,4 comprise a binder, the binder may be driven off by using the samefurnace as used for the sintering or by using a separate debindingequipment.

According to another embodiment, the pre-manufactured coherent bodiesare coherent shells which contain metallic powder. FIG. 5 showsschematically a coherent body according to the second embodiment, inthis case the cladding layer 4. The entire outer surface of body 4, isconsolidated into a coherent shell 9 which encloses a volume of metallicpowder 10. The thickness of the shell may for example be 1-3 mm thickdepending on the dimensions of the body. The shell 9 forms a containerwhich holds the metallic powder. Depending on the manufacturing method,the metallic powder enclosed by the shell may be loose metallic powderor metallic powder which is sintered.

Pre-manufactured coherent bodies in the form of shells may also bemanufactured by 3D-printing, i.e. by placing discrete layers of metallicpowder on top of each other. However, in this case only the periphery ofthe layers is subjected to laser sintering so that only the outersurface of the final body is consolidated. A suitable machine for thispurpose is EOS M 400 which is commercially available from EOS GmbH. Inthis case the shell consists of coherent sintered metallic power and themetallic powder which is enclosed by the shell is loose metallic powder,i.e. it is not sintered.

It is also possible form the shell by consolidating the metallic powderin the periphery of the layers by electron beam (EB) melting followed bycooling. This may be achieved in an Arcam Q20 apparatus which iscommercially available from the company Arcam AB. In this case the shellconsists of coherent melted and solidified metallic power and themetallic powder in the shell is sintered to a low degree by the heatgenerated by the electron beam process.

After arranging the pre-manufactured coherent bodies of metallic powdermaterial 1, 2, 3, 4 in the capsule 5, the capsule is closed by arranginga lid 6 on top of the capsule. The lid is welded to the capsule and avacuum is drawn in the capsule. Finally, the capsule is sealed bywelding any openings shut. After welding, the capsule should begas-tight.

In a third step 300, the filled capsule is subjected to Hot IsostaticPressing for a predetermined time, at a predetermined pressure and apredetermined temperature so that the metallic material is densified.During HIP, the pre-manufactured coherent bodies 1, 2, 3, 4 and thecapsule 5 bond metallurgical to each other whereby a dense, diffusionbonded, coherent HIP:ed metallic component is achieved.

The filled and sealed capsule 5 is thereby placed in a HIP-chamber 80,see FIG. 3. The HIP-chamber is pressurized with gas, e.g. argon gas, toan isostatic pressure in excess of 500 bar. Typically the isostaticpressure is between 900-1200 bar. The chamber is heated to a temperaturewhich is below the melting point of the lowest melting material orphases that may form. The closer to the melting point the temperatureis, the higher the risk for the formation of melted material andunwanted phases. Therefore, the temperature should be as low as possiblein the furnace during HIP:ing. However, at low temperatures thediffusion process slows down and the material will contain residualporosity and the metallurgical bond between the particles becomes weak.Therefore, the temperature is preferably between 100-300° C. below themelting point of the lowest melting material, for example between900-1150° C., or 1000-1150° C. The diffusion processes that take placebetween the materials in the capsule during HIP:ing are time dependentso long times are preferred. Too long times could lead to poorproperties of the HIP:ed material due to e.g. grain growth or excessivedissolution of phases. Preferable, HIP process should be earned out fora time period of 0.5-4 hours, depending on the cross-sectionaldimensions of the component in question.

In an optional step 500, after HIP and cooling, the capsule 5 and thelid 6 may be removed from the metallic component 50, for example bypickling or machining.

Although particular alternatives and embodiments have been described indetail, this has been done for illustrative purposes only and is notintended to be limiting. In particular it is contemplated that varioussubstitutions, alterations and modifications may be made within thescope of the appended claims.

For example, instead of manufacturing complete pre-manufactured coherentbodies of metallic powder, it is also possible to manufacturing a body,for example the valve seat, in sections and arranging the sections inthe capsule. This could be necessary when large components aremanufactured since the 3D printing machines put limitations to themaximum size of the bodies.

When a solid, i.e. forged core body 2 is used, the core body could forma part of the capsule. In this case the capsule is welded to the solidcore body 2 which for example forms the bottom of the capsule.

What is claimed is:
 1. A method for manufacturing a metallic component,comprising the steps of: manufacturing a pre-manufactured coherent bodyby Additive Manufacturing including sequentially superimposing layers ofa first metallic powder, wherein the pre-manufactured coherent bodyincludes at least a portion of the first metallic powder consolidatedsuch that the first metallic powder is held together into thepre-manufactured coherent body with a binder; sintering thepre-manufactured coherent body in a sintering furnace to form a sinteredpre-manufactured coherent body, wherein the sintering temperature isbelow the melting point of the first metallic powder and is sufficientto drive off the binder from the pre-manufactured coherent body;arranging the sintered pre-manufactured coherent body and a metallicmaterial in a capsule which defines at least a portion of a shape of themetallic component; sealing the capsule to be gas-tight; and subjectingthe capsule to Hot Isostatic Pressing at an isostatic pressure between900-1200 bar and at a HIP temperature between 100-300° C. below a lowestmelting point of any of the first metallic powder and the metallicmaterial and for a time period of 0.5-4 hours.
 2. The method of claim 1,wherein a porosity of the sintered pre-manufactured coherent bodymatches a porosity of loose metallic powder.
 3. The method of claim 1,wherein the metallic material is a loose powder.
 4. The method of claim1, wherein the metallic material is a consolidated powder.
 5. The methodof claim 1, wherein the metallic material includes anotherpre-manufactured coherent bodies.
 6. The method of claim 1, wherein themetallic material includes at least three pre-manufactured coherentbodies.
 7. The method of claim 1, wherein the HIP temperature is between900-1150° C.
 8. The method of claim 1, wherein the entirepre-manufactured coherent body is manufactured by AdditiveManufacturing.
 9. The method of claim 1, wherein the entirepre-manufactured coherent body is sintered metallic powder.
 10. Themethod of claim 1, wherein Additive Manufacturing is 3D-printing. 11.The method of claim 1, further comprising drawing a vacuum on thecapsule prior to sealing the capsule to be gas-tight.
 12. The method ofclaim 1, further comprising, subsequent to subjecting the capsule to HotIsostatic Pressing, the step of cooling the capsule and removing thecapsule.
 13. The method of claim 1, wherein the first metallic powderhas a composition including alloyed steel having a carbon content offrom 0.15-0-35 wt % carbon and the metallic material has a compositionincluding low carbon steel having a carbon content of from 0-0.09 wt %carbon.
 14. The method of claim 13, wherein the composition of themetallic material further includes 12-25 wt % chromium.
 15. The methodof claim 1, wherein the metallic component is a valve spindle, the valvespindle including a valve disc and a valve stem, wherein the capsuledefines at least a portion of the valve disc, and the metallic materialincludes a valve seat and a core body having a core head, a claddinglayer and a buffer layer arranged on the core head, and wherein at leastone of the valve seat, the buffer layer and the cladding layer arecoherent pre-manufactured bodies of metallic powder.
 16. The method ofclaim 15, wherein the core body is a forged body.
 17. A method formanufacturing a metallic component, comprising the steps of:manufacturing a pre-manufactured coherent body, wherein at least aportion of the pre-manufactured coherent body is manufactured by (i)Additive Manufacturing including sequentially superimposing layers of afirst metallic powder and (ii) consolidating a portion of the firstmetallic powder to form an outer shell enclosing an interior volume,wherein the interior volume contains a powder including the firstmetallic powder, a second metallic powder, or a mixture thereof;sintering the pre-manufactured coherent body in a sintering furnace toform a sintered pre-manufactured coherent body, wherein the sinteringtemperature is below the melting point of the first metallic powder andis sufficient to drive off the binder from the portion of thepre-manufactured coherent body manufactured by Additive Manufacturing;arranging the sintered pre-manufactured coherent body in a capsule whichdefines at least a portion of a shape of the metallic component; sealingthe capsule to be gas-tight; and subjecting the capsule to Hot IsostaticPressing at an isostatic pressure between 900-1200 bar and at a HIPtemperature between 900-1150° C. and for a time period of 0.5-4 hours.18. The method of claim 17, wherein consolidating includes sintering.19. The method of claim 17, wherein consolidating includes melting usinga laser beam and cooling.
 20. The method of claim 17, whereinconsolidating includes melting using an electron beam and cooling. 21.The method of claim 17, wherein the powder enclosed by the shell isloose powder.
 22. The method of claim 17, wherein the powder enclosed bythe shell is sintered powder.
 23. The method of claim 17, wherein aporosity of the outer shell matches a porosity of the powder containedin the interior volume.
 24. The method of claim 17, wherein the HIPtemperature is below a lowest melting point of any of the first metallicpowder and the second metallic powder.
 25. The method of claim 17,further comprising arranging a metallic material in the capsule adjacentto one or more surfaces of the sintered pre-manufactured coherent body.26. The method of claim 25, wherein the metallic material is anotherpre-manufactured coherent body that includes an outer shell ofconsolidated metallic material.
 27. The method of claim 25, wherein themetallic material includes at least three pre-manufactured coherentbodies.
 28. The method of claim 25, wherein the metallic material is aloose powder.
 29. The method of claim 25, wherein the metallic materialis a consolidated powder.
 30. The method of claim 25, wherein a porosityof the metallic material matches a porosity of the outer shell of thesintered pre-manufactured coherent body.
 31. The method of claim 25,wherein the HIP temperature is below a lowest melting point of any ofthe first metallic powder, the second metallic powder, and the metallicmaterial.
 32. The method of claim 23, wherein first metallic powder hasa composition including alloyed steel having a carbon content of from0.15-0-35 wt % carbon and the metallic material has a compositionincluding low carbon steel having a carbon content of from 0-0.09 wt %carbon.
 33. The method of claim 32, wherein the composition of themetallic material further includes 12-25 wt % chromium.
 34. The methodof claim 17, further comprising drawing a vacuum on the capsule prior tosealing the capsule to be gas-tight
 35. The method of claim 17, furthercomprising, subsequent to subjecting the capsule to Hot IsostaticPressing, the step of cooling the capsule and removing the capsule. 36.The method of claim 17, wherein Additive Manufacturing is 3D-printing.37. The method of claim 17, wherein the metallic component is a valvespindle, the valve spindle including a valve disc and a valve stem,wherein the capsule defines at least a portion of the valve disc, andthe metallic material includes a valve seat and a core body having acore head, a cladding layer and a buffer layer arranged on the corehead, and wherein at least one of the valve seat, the buffer layer andthe cladding layer are coherent pre-manufactured bodies of metallicpowder.
 38. The method of claim 37, wherein the core body is a forgedbody.